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09-12-2016 11:47 AM Willys - Electrical Wrap-Up
Once the interior was completed, it was time to finish up the electrical wiring. The rear interior panels were removed to allow access to the rear electrical components. Also, the center console and dash panels were removed.
The first two photos show the rear bulkhead area and the wood framing that the interior shop used to support the panels. Battery cable routing was finished up and battery was installed.
The third photo shows the wiring behind the left dash panel. The master cylinders for the brakes and clutch can be seen, as well as the connectors for the instruments so that the panel can be removed easily. Also seen is just one of the many ground blocks that is required for a fiberglass-bodied car.
The fourth photo shows the wiring at the center console for the window switches, stereo head unit and A/C control panel. The plastic tubing shown at the left of the photo goes to the vacuum/boost gauge located in the center panel.
The fifth photo shows the weatherpack connectors for the parking and head lights. These connectors will make it easier to remove the entire tilt front shell if needed.
The last photo shows a last minute change in the ignition circuit. I originally had a Hunt mag-look HEI distributor installed on the Hemi, but there were compatibility issues with the Holley HP fuel injection electronics. So, a change in distributors necessitated using a remote ignition coil. A place was found on the firewall for the MSD Blaster unit.


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  [Entry #228]

09-12-2016 11:39 AM Willys - Interior Finished
We got the Willys back from Bux Customs in Pottstown PA, and were very pleased with the final result. Total time in the shop was 16 weeks. Interior is black leather with distressed burgundy leather for the accent color. Carpeting is black Daytona weave. The original thought was to paint the sub-dash, but the contrasting brushed aluminum looked better. Sub-dash houses the A/C vents, push buttons for line lock, tilt actuators and trunk release, and the control knobs for lighting and wipers.
The center floor console houses the window switches, a cup holder and inside the slide cover is the e-brake lever. The shifter is from Gennie Shifter and includes a Speed Dawg knob with line lock button.
The upper console ahead of the shifter houses the Pioneer Stereo head unit, 12 volt power port, and the A/C control knobs. All stitching on the seats was done in a contrasting red thread. The trunk area was carpeted throughout with black Daytona weave.
Bux did a great job in creating the interior panels to fit around the roll bar. All panels are easily removable to access the battery and electrical components.


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  [Entry #227]

06-17-2015 09:41 AM Willys - Fuel Tank Foam
The fuel tank for the Willys is a total of 19 gallons, with an internal mounted fuel pump and filter. Aside from the bottom sump area for the fuel pickup, there is no baffling inside the tank. I decided to add fuel cell safety foam to the inside of the tank, not only to avoid a lot of sloshing around, but also to keep the fuel sender float steadier. The foam was an easier alternative than fabricating some sheet metal style baffles that would be difficult to install/remove in case the fuel pump had to come out, or more likely the fuel filter needing to be serviced. I gave a call to the fuel cell foam manufacturer just to verify that I would have no problem with any decomposition of the foam with E10 pump gas. I also verified with the fuel injector manufacturer to make sure that the foam would not give the injectors any problems. After making sure that the foam was okay to use, I purchased a universal kit that came with a few different sized foam blocks that would be cut to shape to fit the tank.
I also wanted a way of making sure that the foam wouldn't move around inside the tank, especially around the fuel sender float. I had some aluminum brackets left over from another project that fit perfectly onto the same mounting studs for the fuel pump. I added a few horizontal aluminum bars to the vertical brackets, and then measured and the cut the foam blocks to fit. Cutouts were made in each block as necessary to provide clearance around the rollover vent valve, the fuel sender float, and the fuel pump suction and discharge tubing. The foam compressed easily enough to fit through the tank opening, and once all of the foam was situated correctly, the brackets and bars were bolted in place. The foam supposedly takes up less than 4% of the total tank volume, so I'm not losing out on very much fuel capacity at all.
The first two photos show the brackets mounted on the fuel pump and filter studs. The pump is just about in the center of the tank, so I was able to get a good sized block to fit on either side of the pump. The third and fourth photos show the completed blocks of foam after ''carving''. The last two photos show the installed foam and arms to keep everything in place.


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  [Entry #226]

05-24-2015 07:42 AM Willys - Interior Progress
The quality of work that Bux is doing is exceeding our expectations. Here are a few in-progress photos of the interior work so far.
The first two photos show the trunk just about finished, with a little more carpet work yet to do. The third photo shows a completed door panel. We chose black leather for most of the interior trim, with burgundy distressed leather for some accent pieces. We let Bux come up with the design elements, and we're very happy with the results. The last two photos show the passenger compartment work in progress, with the window trim installed and the headliner finished. Still to come are the remaining interior panels, seat upholstery and console work.


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  [Entry #225]

05-24-2015 07:37 AM Willys - Out to Trim Shop
It was time to load the Willys up one more time for the trip to the Interior trim shop. It was late March here in the northeast, and we still had snow. We're getting better at the loading/tying-down/unloading routine.
The Interior shop we chose was Chris McClintock's Bux Customs in Pottstown, PA. We did a lot of searching and met with more than a few interior guys before we settled on Bux. He was on the same page with us from the start, and understood what we were looking for in the interior design. We had previously been out to his shop to discuss the project and had already picked out the coverings and carpet. We got the Willys into Chris' new shop and left there confident in our choices.


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  [Entry #224]

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